What does cable assembly mean in the automotive industry?
In the automotive sector, cable assembly means the specialized manufacture and assembly of electrical connections and cable systems which meet the specific requirements and technical specifications of the industry. These systems are indispensable to the networking of different electrical and electronic systems in vehicles, from basic lighting systems to complex control devices and high-speed data transmission in modern on-board networks.
Roles in modern on-board networks
In modern vehicle on-board networks, in addition to wiring for power distribution, wiring for data transmission is playing an increasingly important role. In particular, the increasing integration of Ethernet-based connections and the introduction of real-time communication protocols, as required for autonomous driving and advanced driver assistance systems (ADAS), is significantly increasing the complexity of these systems.
Production processes
While basic processes, such as cutting cables to length, has generally been automated for a while now, the final assembly of cable harnesses was still being carried out manually until just a few years ago. However, the emerging trend is to automate increasingly more steps to increase accuracy, reduce bottlenecks in production and enhance efficiency. Automated processes make it possible to keep to the narrower tolerances. This is particularly important in the production of miniaturized connectors and high-density cable harnesses that are required in modern vehicles. In addition, automation is improving the traceability of each cable and each component, which contributes to enhancing quality assurance and observing safety standards.
Future developments in cable assembly
Zone architecture represents a significant change in the development of on-board networks as it divides the vehicle into several zones, each of which have their own zone computer and are connected to adjacent components via compact, local cable harnesses. At the same time, the demands on each individual data connection are increasing, as particularly reliable and powerful data transmission is indispensable, especially for the autonomous driving functions of the future. For cable assembly, this means that production must become more flexible and modular as the increased decentralization of wiring means that everything must be adapted to the specific requirements of each zone and must therefore be manufactured individually.
Further automation and standardization of production processes will be introduced to effectively meet the different requirements of zone architecture. Automated production facilities must be able to produce smaller, more accurate components, adapted to the specific zones. MES (Manufacturing Execution Systems) will play a key role in terms of monitoring production in real time and making quick adjustments. The use of automated optical inspection systems and intelligent production robots will improve precision and enable an increasingly comprehensive examination of each individual component.